Fluidic Control System and Method of Manufacture

ABSTRACT

A fluidic control system includes featured layers. The featured layers include two or more features which collectively form at least one functional component.

CROSS-REFERENCED TO RELATED APPLICATION

The present application is a divisional application of U.S. patentapplication Ser. No. 12/053,374, filed on Mar. 21, 2008. The applicationis incorporated by reference herein in their entirety.

TECHNICAL FIELD

The present document relates to control systems. More specifically, itrelates to a fluidic control system.

BACKGROUND

Trends in technology are progressing towards smaller scales for systemsin a variety of applications. Fluidic systems can be integrated withinrestrictive form factors imposed by the system to manipulate thetransport of fluid. For example, flow-modulating components can bearranged for functions such as reactant delivery, heat transfer, anddosing of fluids.

Electronic components, such as personal electronic devices, are trendingto become smaller in size. As electronic components are designed insmaller in size and incorporate sophisticated and complex technology,the demands on the power supply become greater. For instance, the powersupply may need to occupy less volume or a smaller footprint toaccommodate the addition of the technology to the device. The additionaltechnology may also require that the power supply last for longerperiods of time. In addition, portable electronic device may need tohave energy storage maintained while the power supply shrinks.

An example of a power supply for the electronic components is a fuelcell system. In order to make a smaller fuel cell system, manyindividual components of the system, such as a fluid delivery componentcan be made smaller, but need to meet the technical requirements of thefuel cell system. For instance, the fluid delivery component may need tomaintain a certain pressure, without occupying an overall significantvolume of the fuel cell system, and without interfering with theassembly of the fuel cell system. Furthermore, the functionality of thefuel cell system must not be compromised.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates an exploded view of a electrochemical cell system asconstructed in accordance with at least one embodiment.

FIG. 1B illustrates a block diagram of a electrochemical cell system inaccordance with at least one embodiment.

FIG. 2 illustrates an exploded perspective view of a fluid manifold asconstructed in accordance with at least one embodiment.

FIG. 3A illustrates a cross-sectional view of a conduit layer asconstructed in accordance with at least one embodiment.

FIG. 3B illustrates a cross-sectional view of a conduit layer asconstructed in accordance with at least one embodiment.

FIG. 3C illustrates a cross-sectional view of a conduit layer asconstructed in accordance with at least one embodiment.

FIG. 4 illustrates a cross-sectional view of a pressure regulator asconstructed in accordance with at least one embodiment.

FIG. 5 illustrates a cross-sectional view of a check valve component asconstructed in accordance with at least one embodiment.

FIG. 6 illustrates a cross-sectional view of a flow valve component asconstructed in accordance with at least one embodiment.

FIG. 7A illustrates a perspective view of a fluidic control system asconstructed in accordance with at least one embodiment.

FIG. 7B illustrates a cross-sectional perspective view of a fluidiccontrol system as constructed in accordance with at least oneembodiment.

FIG. 7C illustrates an exploded perspective view of a fluidic controlsystem as constructed in accordance with at least one embodiment.

FIG. 8A illustrates a perspective view of a fluidic control system asconstructed in accordance with at least one embodiment.

FIG. 8B illustrates an exploded perspective view of a fluidic controlsystem as constructed in accordance with at least one embodiment.

FIG. 9 illustrates a system configuration for a fluidic control systemas constructed in accordance with at least one embodiment.

FIG. 10 illustrates a view of an enclosure with an interface asconstructed in accordance with at least one embodiment.

FIG. 11 illustrates a side view of an enclosure with an interface asconstructed in accordance with at least one embodiment.

FIG. 12 illustrates a cross-sectional view of a electrochemical cellsystem in accordance with at least one embodiment.

FIG. 13 illustrates a fuel flow velocity within the electrochemical cellsystem of FIG. 12, which includes an array of fluidic pressure regulatordevices and an array of anode cavity inlets, as constructed inaccordance with at least one embodiment.

DETAILED DESCRIPTION

The following detailed description includes references to theaccompanying drawings, which form a part of the detailed description.The drawings show, by way of illustration, specific embodiments in whichthe fluid manifold and fluidic control systems and methods may bepracticed. These embodiments, which are also referred to herein as“examples,” or “options” are described in enough detail to enable thoseskilled in the art to practice the present invention. The embodimentsmay be combined, other embodiments may be utilized or structural orlogical changes may be made without departing from the scope of theinvention. The following detailed description is, therefore, not to betaken in a limiting sense and the scope of the invention is defined bythe appended claims and their legal equivalents.

In this document, the terms “a” or “an” are used to include one or morethan one, and the term “or” is used to refer to a nonexclusive “or”unless otherwise indicated. In addition, it is to be understood that thephraseology or terminology employed herein, and not otherwise defined,is for the purpose of description only and not of limitation.

DEFINITIONS

As used herein, “fluid” refers to a continuous, amorphous substancewhose molecules move freely past one another and that has the tendencyto assume the shape of its container. A fluid may be a gas, liquefiedgas, liquid or liquid under pressure. Examples of fluids may includefluid reactants, fuels, oxidants, and heat transfer fluids. Fluid fuelsused in fuel cells may include hydrogen gas or liquid and hydrogencarriers in any suitable fluid form. Examples of fluids include air,oxygen, water, hydrogen, alcohols such as methanol and ethanol, ammoniaand ammonia derivatives such as amines and hydrazine, silanes such asdisilane, trisilane, disilabutane, complex metal hydride compounds suchas aluminum borohydride, boranes such as diborane, hydrocarbons such ascyclohexane, carbazoles such as dodecahydro-n-ethyl carbazole, and othersaturated cyclic, polycyclic hydrocarbons, saturated amino boranes suchas cyclotriborazane, butane, borohydride compounds such as sodium andpotassium borohydrides, and formic acid.

As used herein, “fluid enclosure” may refer to a device for storing afluid. The fluid enclosure may store a fluid physically or chemically.For example, the fluid enclosure may chemically store a fluid in activematerial particles.

As used herein, “active material particles” refer to material particlescapable of storing hydrogen or other fluids or to material particlesthat may occlude and desorb hydrogen or another fluid. Active materialparticles may include fluid-storing materials that occlude fluid, suchas hydrogen, by chemisorption, physisorption or a combination thereof.Some hydrogen-storing materials desorb hydrogen in response to stimuli,such as change in temperature, change in heat or a change in pressure.Examples of hydrogen-storing materials that release hydrogen in responseto stimuli, include metal hydrides, chemical hydrides, suitablemicro-ceramics, nano-ceramics, boron nitride nanotubes, metal organicframeworks, palladium-containing materials, zeolites, silicas, aluminas,graphite, and carbon-based reversible fluid-storing materials such assuitable carbon nanotubes, carbon fibers, carbon aerogels, and activatedcarbon, nano-structured carbons or any combination thereof. Theparticles may also include a metal, a metal alloy, a metal compoundcapable of forming a metal hydride when in contact with hydrogen, alloysthereof or combinations thereof. The active material particles mayinclude magnesium, lithium, aluminum, calcium, boron, carbon, silicon,transition metals, lanthanides, intermetallic compounds, solid solutionsthereof, or combinations thereof.

As used herein, “metal hydrides” may include a metal, metal alloy ormetal compound capable of forming a metal hydride when in contact withhydrogen. Metal hydride compounds can be generally represented asfollows: AB, AB₂, A₂B, AB₅ and BCC, respectively. When bound withhydrogen, these compounds form metal hydride complexes.

As used herein, “occlude” or “occluding” or “occlusion” refers toabsorbing or adsorbing and retaining a substance, such as a fluid.Hydrogen may be a fluid occluded, for example. The fluid may be occludedchemically or physically, such as by chemisorption or physisorption, forexample.

As used herein, “desorb” or “desorbing” or “desorption” refers to theremoval of an absorbed or adsorbed substance. Hydrogen may be removedfrom active material particles, for example. The hydrogen or other fluidmay be bound physically or chemically, for example.

As used herein, “contacting” refers to physically, chemically,electrically touching or within sufficiently close proximity. A fluidmay contact an enclosure, in which the fluid is physically forced insidethe enclosure, for example.

A fluidic control system is provided herein. The fluidic control systemprovides an effective structure and method of controlling thedistribution of fluid, for example, in a small volume of space. Thefluidic control system is formed of thin layers of material, such aslayers having a thickness of about 10 to 500 micron.

The fluidic control system is formed of one or more featured layers,where one or more of the layers have features. In an option, thefeatures of the featured layers form functional components of thesystem. In an option, the system includes at least two functionalcomponents, where features of any of the two or more featured layerscollectively form the functional components. In yet another option,functional component is formed by the interaction of features formed intwo or more layers, or two to four layers, where the component functionis achieved by the displacement of at least one feature out of its planeand into the plane of another featured layer. For example, the featuremay be mechanically displaced orthogonal to the plane of the features.

In a further option, the functional components are co-planar with eachother. In yet another option, the two or more features include an arrayof features fluidly communicating with each other within a common plane.Examples of the functional components for the fluidic control systeminclude, but are not limited to, at least one of a pressure regulatorcomponent, a check valve component, a flow valve component, a chargevalve component, a pressure relief component, a conduit, an on/offvalve, a manual on/off valve, or a thermal relief component.

In an example embodiment, the fluidic control system, including thefunctional components discussed above and below, can be used with atleast one fluid enclosure communicatively coupled with the fluidiccontrol system.

In an example embodiment, the fluidic control system can be used withinan electrochemical cell system, such as a fuel cell system, for instanceas illustrated in FIG. 1A. Although the term fuel cell system is usedherein, it should be noted that the system can be used for anyelectrochemical cell system. The fuel cell system 100 includes, but isnot limited to, one or more of a fuel cell 102, a fluidic control system104, a charge port 106, a fluid enclosure such as fuel reservoir 108,and a fluid manifold 120.

The fuel reservoir 108 provides fuel for the fuel cell 102, which can becharged or refueled via the charge port 106. The fluidic control system104 provides for the distribution and regulation of fuel, as will befurther described below. The fluid manifold 120 provides a conduit forthe fuel between the fluidic control system 104, the fuel cell 102, andthe fuel reservoir 108. The fluid manifold can also be used todistribute other fluids, including, but not limited to, heat transferfluid.

The fluid enclosure such as a fuel reservoir, can have a variety offorms. In an option, the fluid enclosure is flexible. Furthermore, thefluid enclosure can be protected with one or more pressure reliefcomponent of the self-destructive type, such as fusible triggers,rupture disks and diaphragms, or of the re-sealable type, such asspring-loaded pressure-relief valve. A pressure relief component may be“pressure-activated”, set to activate at a certain pressure.Alternately, a pressure relief component may be “thermally-activated”,set to activate at a certain temperature. A pressure relief componentmay also be both “pressure-activated” and “thermally-activated”. Stillfurther, the fluid enclosure can be protected with a thermal reliefcomponent.

In a further option, the fluid enclosure can include fuel cartridges,such as replaceable fuel cartridges. The cartridges may includedispenser cartridges, disposable fuel ampoules, refillable fuel tanks orfuel cell cartridges, for example. The fuel cartridge may include aflexible liner that is connectable to a fuel cell or fuel cell layer.The fuel cartridge may also include a connecting valve for connectingthe cartridge to a fuel cell, fuel cell layer or refilling device.Examples of valves can be found in commonly owned co-pending patentapplication entitled REFUELING VALVE FOR A FUEL STORAGE SYSTEM ANDMETHOD THEREFOR, filed on Jan. 9, 2007, having Ser. No. 11/621,542, andattorney docket no. 2269.003US1 which is incorporated by reference inits entirety.

In a further option, the fluid enclosure can be used in a system with aninterface. The system optionally includes a strain absorbing interfacefor contacting the fluid enclosure. For instance, the interface is usedfor a rigid or semi-rigid component and a flexible fluid enclosure. Theinterface absorbs any strain due to dimensional changes in the fluidenclosure as it charges with hydrogen. Additional examples and detailscan be found in commonly owned co-pending patent application entitledINTERFACE FOR FLEXIBLE FLUID ENCLOSURES, filed even date herewith,having Ser. No. 12/052,829 and patented as U.S. Pat. No. 7,926,650, andhaving attorney docket no. 2269.063US1 which is incorporated byreference in its entirety.

Rigid components, such as mounts or fluidic devices for fuel cellcommunication, can be coupled to the fluid enclosure through theflexible interface and not risk sheering due to mechanical stress. Theflexible interface allows for more component configurations andapplications for use with a flexible fluid enclosure. The flexibleinterface absorbs strain and supports the connection between componentand enclosure.

For instance, referring to FIG. 10, a cross-sectional view of a fluidenclosure interface system 400 is shown, according to some embodiments.The system 400 includes a flexible fluid enclosure 406 in contact with astrain absorbing interface 404 on a first side. On a second side, theinterface 404 may be in contact with a featured layer 402. The featuredlayer may include a plurality of featured layers, or one or morefeatured layers that collectively form a functional component. Anoptional fluidic connection 408 may be positioned in the interface 404,connecting the enclosure 406 and featured layer 402.

The fluid enclosure 406 may be an enclosure formed by conformablycoupling an outer wall to a composite hydrogen storage material, forexample. Conformably coupled refers to forming a bond that issubstantially uniform between two components and are attached in such asway as to chemically or physically bind in a corresponding shape orform. A structural filler or composite hydrogen storage material may beconformably coupled to an outer enclosure wall, for example, in whichthe outer enclosure wall chemically or physically binds to thestructural filler or composite hydrogen storage material and takes itsshape. The outer enclosure wall is the outermost layer within a fluidenclosure that serves to at least partially slow the diffusion of afluid from the enclosure. The outer enclosure wall may include multiplelayers of the same or differing materials. The outer enclosure wall mayinclude a polymer or a metal, for example.

The fluid may be hydrogen, for example. Additional examples and detailsregarding the enclosure can be found in commonly owned co-pendingentitled FLUID ENCLOSURE AND METHODS RELATED THERETO, filed Jun. 23,2006, having Ser. No. 11/473,591, and having attorney docket no.2269.017US1 which is incorporated by reference in its entirety.

A composite hydrogen storage material refers to active materialparticles mixed with a binder, wherein the binder immobilizes the activematerial particles sufficient to maintain relative spatial relationshipsbetween the active material particles. Active material particles arematerial particles capable of storing hydrogen or material particlesthat may occlude and desorb hydrogen, such as metal hydrides, forexample. The active material may be a metal, metal alloy or metalcompound capable of forming a metal hydride when in contact withhydrogen. For example, the active material may also include a metal, ametal alloy, a metal compound capable of forming a metal hydride when incontact with hydrogen, alloys thereof or combinations thereof. Theactive material particles may include magnesium, lithium, aluminum,calcium, boron, carbon, silicon, transition metals, lanthanides,intermetallic compounds, solid solutions thereof, or combinationsthereof.

The active material particles may occlude hydrogen by chemisorption,physisorption or a combination thereof. Active material particles mayalso include silicas, aluminas, zeolites, graphite, activated carbons,nano-structured carbons, micro-ceramics, nano-ceramics, boron nitridenanotubes, palladium-containing materials or combinations thereof.Examples of composite hydrogen storage materials can be found incommonly-owned U.S. patent application Ser. No. 11/379,970, filed Apr.24, 2006, which is incorporated by reference.

The strain absorbing interface 404 may be manufactured of any suitablematerial that allows it to be flexible, absorb strain and bond to theenclosure 406 and featured layer 402. The material chosen should providea suitable bond, physical or chemical, between the featured layer 402and enclosure 406 and also allow for the differential in strain betweenthe strain of the enclosure wall and the rigidity of the featured layer402, so that the sheer stress on any bonds does not exceed the strengthof such bonds. The interface 404 may be manufactured of an elastomericmaterial or silicon material, for example. Elastomeric materials mayinclude thermoplastic elastomers, polyurethane thermoplastic elastomers,polyamides, melt processable rubber, thermoplastic vulcanizate,synthetic rubber and natural rubber, for example. Examples of syntheticrubber materials may include nitrile rubber, fluoroelastomers such asViton® rubber (available from E.I. DuPont de Nemours, a Delawarecorporation), ethylene propylene diene monomer rubber (EPDM rubber),styrene butadiene rubber (SBR), and Fluorocarbon rubber (FKM).

As the fluid enclosure 406 is filled with fluid, or occluded by acomposite fluid storage material, the dimensions of the enclosure 406increase (see FIG. 11). The strain absorbing interface 406 may deform orchange in dimension, such as in thickness 412. The strained interface414 then maintains a consistent, less stressful contact between theenclosure 406 and featured layer 402. The featured layer 402 would thenundergo little to no strain, as the interface 414 absorbs strain causedby the enclosure 406 movements. The interface 414 may absorb all or atleast part of the strain caused by changes in dimension of enclosure406.

The featured layer 402 may be any fitting, mount, connector, valve,regulator, pressure relief component, planar microfluidic device, aplate, any device that might control the flow of hydrogen into or out ofthe enclosure or combinations thereof, for example. Multiple interfaces404 and multiple featured layers 402 may be utilized in conjunction withone or more fluid enclosures 406, where the featured layers formfunctional components such as, but not limited to, the fluidic controlsystem, the manifold, the pressure regulator, the check valve. Inanother option, the interfaces 404 can be coupled with an inlet of thefluidic control system, the fuel cell, or the fluidic enclosure.

FIG. 1B illustrates additional examples for the system 100 and themanifold 118. The fuel cell system 100 includes a fluid enclosure 114fluidly coupled with one or more fluid control components, by a manifold118. The one or more fluid control components can include, but are notlimited to a fluidic control system, at least one of a pressureregulator component, a check valve component, a flow valve component, acharge valve component, a pressure relief component, a conduit, anon/off valve, a manual on/off valve, or a thermal relief component.

The one or more fluid control components, such as the pressure regulatorcomponent 116, is fluidly coupled with a fuel cell 102 via a manifold118. The manifold 118 includes one or more conduit channels 130 therein.In a further option, the manifold 118 is fluidly coupled with the one ormore fluid control components, such as the pressure regulator 116, andis fluidly coupled with the fuel cell 102, and can further include atleast one feedback channel 129 and a delivery channel 133. The deliverychannel 133 delivers fluid such as a fuel to the fuel cell 102. Thefeedback channel 129 allows for the regulator to be piloted based on thefeedback to the pressure regulator 116 from pressure in the fuel plenum,and is fluidly coupled to a fluid plenum of the fuel cell system. Eachof the components of the fuel cell system 100 can be formed by theflexible layered structured as discussed above and below. In a furtheroption, the one or more conduit channels 130 include a gas conduitchannel, or a feedback channel.

Further options for the system 100 are as follows. For instance, acomponent for a fluidic control system, includes two or more featuredlayers having features. The features include a valve having a position,and a fluid flow through the functional component is controllable basedon the position of the valve. The system further includes a flexiblefeature that is actuatable in response to a sensory fluid pressure,where a position of the flexible feature proportionally controls thevalve position. The flexible feature optionally has elastic properties.The flexible feature, in an option, is integrated with a second pressureplenum. In a further option, the flexible feature restricts flow throughthe fluidic control system component between a predefined range ofsensory fluid pressures. In yet a further option, a spring member is incontact with the flexible feature.

Sensory fluid pressure, in an option, refers to any pressure thatcontrols the valve position. The sensory fluid pressure can include apressure upstream or downstream of the valve, a pressure of a fluidplenum such as a fuel plenum of a fuel cell, environmental pressure, anyother pressure within the system, pressure differentials, andcombinations thereof. The sensory fluid pressure, in an option, includesa pressure downstream of the valve. In another option, the sensory fluidpressure includes a pressure in the low pressure plenum, and/or thesensory fluid pressure includes a pressure in the high pressure plenum.In yet a further option, the sensory fluid pressure is a fluid pressureof a fluidic plenum of at least one fuel cell.

The features of the featured layers optionally include at least twofluid plenums including a first pressure plenum and a second pressureplenum, where optionally the first pressure plenum is a high pressureplenum receiving unregulated fluid, and the second pressure plenum is alow pressure plenum receiving regulated fluid. Alternately, the firstpressure plenum may be a high pressure plenum receiving regulated fluid,and the second pressure plenum may be a low pressure plenum receivingunregulated fluid. In an option, a position of the flexible featureproportionally controls the position of the valve, and controls a flowof fluid between the first pressure plenum and the second pressureplenum. Further options for multiple plenums are as follows.

As shown in cross-section in the example of FIG. 12, a fuel cell layer602 is arranged to one side of a dual system plenum 504, including ahigher pressure fluid reservoir 608 and a lower pressure anode cavity609 separated by the array 502 of fluidic pressure regulator devices604. In one example, the dual system plenum 504 has approximately thesame dimensions as the fuel cell layer 602, with the fuel cell layer 602in direct fluidic communication with the anode cavity 609.

In operation, fuel or other fluid is allowed to enter the higherpressure fluid reservoir 608 via a charge port or inlet 606. Optionally,there may be a fluidic pressure regulator device or other fluid controlelement at such inlet. This allows for high fuel or other fluidpressures, such as pressures exceeding 30 psi, to exist in the fluidreservoir 608 as these high pressures are not allowed to exert asignificant force on the anodes of the fuel cell layer 602 due to thearray of fluidic pressure regulator devices 604. This means an overallbulk fuel distribution system may be employed, allowing for easycirculation of fuel or other fluid within the fluid reservoir 608 andavoiding the possibility of having local starvation of fuel or otherpowering fluid. Optionally, multiple fluid reservoirs may be connectedto a common inlet so that multiple fuel cell layers can be operated as asingle system. This allows each fuel cell layer to be individuallypressure regulated, eliminating the need for pressure distributionmanagement and allowing for an alternative method of constructingmultiple fuel cell layer assemblies.

When multiple inlets to the anode cavity 609 from the low pressureoutlets 500 of the array 502 of fluidic pressure regulator devices 604are employed, such as in a parallel configuration, there isadvantageously a fluid (e.g., fuel) flow velocity that is uniform ornearly uniform along a length and width of the fuel cell layer 602, asshown in FIG. 13.

Referring again to FIG. 1A, the fluid manifold 120 is fluidly coupledwith the fluidic control system 104 and the fuel reservoir 108, and/orthe fuel cell 102, for example as discussed in co-pending provisionalapplication entitled “FUEL MANIFOLD AND METHODS THEREFOR”, filed Mar.21, 2007, having Ser. No. 60/919,472 and attorney docket number2269.060PV1, and in co-pending application entitled “FLUID MANIFOLD ANDMETHODS THEREFOR”, filed even date herewith, having attorney docketnumber 2269.060US1, and are each incorporated herein by reference in itsentirety.

In an example, the fluid manifold 120 includes a layered structure thatallows for the manifold to be of a size that does not take upunnecessary volume, nor an unnecessarily large footprint, yet allows forthe pressure, volume, and temperature requirements for fuel supplysystems to be met. The fluid manifold 120 can be made of relatively thinlayers of material, allowing for the fluid manifold 120 to be flexible.The flexible manifold can be bent around components, or wrapped aroundcomponents, providing greater number of assembly options for the fuelcell system. In a further option, the fluid manifold 120 can be made aspart of the fluidic control system 104.

FIG. 2 illustrates an example of a portion of a fluid manifold, such asthe fluid manifold 120. This portion of the fluid manifold 120 includesat least one conduit layer 122 defined in part by a first side 124 and asecond side 126. In an option, the at least one conduit layer 122 isrelatively thin, for example, compared with the length and width. In anexample, the thickness of the at least one conduit layer 122 is aboutgenerally less than 1 mm. In another example, the thickness of the atleast one conduit layer 122 is about 50 μm-1 mm. In an example, thewidth and length of the layer 122 is about 1 mm and 100 mm,respectively. In another example, the thickness of the at least oneconduit layer 122 is about 100 μm, and the width and length of the layer122 is about 1 mm and 1.5 mm, respectively. The width and/or the lengthcan be altered for geometry of the system in which the manifold isinstalled.

In a further option, the thickness of the layer is about 10-500 micron,and a dimension of the conduit channel, such as a height or a width or achannel depth, is about 50 micron to 1 mm. The layer is highly planarsuch that a width of the manifold is greater than thirty times thedimension of the conduit channel. In another option, the width of themanifold is greater than three times the dimension of the conduitchannel. It should be noted other ranges are possible.

The at least one conduit layer 122 further includes at least one recess130 therein. The at least one recess 130 is a material directing recessin that it directs the material that flows therethrough. The at leastone recess 130, in an option, extends through the conduit layer 122,from the first side 124 to the second side 126, as shown in FIG. 2, andFIG. 3A. In another option, the at least one recess 130 extends onlypartially within a side of the conduit layer 122, as shown in FIG. 3B.In yet another option, the conduit layer 122 includes two or morerecesses 130. For example, two or more recesses 130 which extend fromthe first side 124 to the second side 126 can be disposed within theconduit layer 122. The two or more recesses 130 can include recessesthat extend partially within a side of the conduit layer 122 (FIG. 3B)and/or the recesses 130 can extend through the layer 122 (i.e. from thefirst side 124 and through the second side 126).

The two or more recesses 130 can be formed within the conduit layer 122such that they do not intersect with one another in the conduit layer122. Alternatively, the two of more recesses 130 can be formed withinthe conduit layer 122 such that they do intersect with one another inthe conduit layer 122. The recess 130 extends along the conduit layer122, and allows for material such as fuel to flow therethrough.

In another option, a first recess 132 can be formed on the first side124 of the conduit layer 122, and a second recess 134 can be farmed onthe second side 126 of the conduit layer 122, where the first recess 132and the second recess 134 do not necessarily extend from the first side124 through to the second side 126. In an example shown in FIG. 3C, thepartial recesses 136 are disposed on opposite sides of the conduit layer122, allowing for material to travel therethrough via the recesses onthe first side 124 and the second side 126.

The conduit layer 122, in another option, is formed of one or more ofmetals, plastics, elastomers, or composites, alone or in combination.The at least one recess 130 is formed within and/or through the layer122, in an option. For example, the at least one recess 130 can beetched or stamped within and/or through the layer 122. In anotheroption, the at least one recess 130 can be drilled within and/or throughthe layer, formed with a laser, molded in the layer 122, die cutting thelayer 122, or machined within and/or through the layer 122. In anoption, the at least one recess 130 has a width of about 20× the depthof the recess. In another option, the at least one recess 130 has awidth of about 1 mm-2 mm. In yet another option, the at least one recesshas a width of about 50-100 μm.

The fluid manifold 120 further optionally includes at least one barrierlayer, and/or a sealing layer 140, as shown in FIG. 2. In a furtheroption, the fluid manifold 120 includes a first sealing layer 142 and asecond sealing layer 144 disposed on opposite sides of the conduit layer122. For example, the first sealing layer 142 abuts and seals againstthe first side 124 of the conduit layer 122, and the second sealinglayer 144 abuts and seals against the second side 126 of the conduitlayer 122. This allows for the recess 130 to be enclosed and form aconduit through which material travels. The sealing layers 142, 144 canbe coupled with the conduit layer 122, for example, but not limited to,using adhesives, bonding techniques, or laser welding. In a furtheroption, the sealing layers 142, 144 and the conduit layer 122 are sealedtogether. For example, the layers 122, 142, 144 are coupled togetherthrough thermal bonding, adhesive bonding, gluing, soldering, welding,ultrasonic welding, diffusion bonding, heat sealing, etc. In a furtheroption, layers 122, 142, 144 are joined by gluing with cyano acrylateadhesive. In yet another option, layers 122, 142, 144 could be built upand selectively etched as is done for MEMs and integrated circuits.

The layers 122, 142, 144, in an option, include one or more bondingregions 369 allowing for flowing adhesives or other bonding agents sothat layers can be bonded without the functional components, the conduitchannels, or ports also being bonded. In a further option, the one ormore featured layers include barrier features, such as, but not limitedto, physical barriers such as ridges, or recesses and/or chemicalbarriers that separate bonding regions from functional regions and/orprevent bonding material from entering function regions.

In a further option, one or more of the sealing layers 142, 144 includesone or more ports 150 therein. For example, the one or more ports 150can include an inlet 152 and an outlet 154. The inlet and outlet 152,154 are positioned within the sealing layer 144 such that they arefluidly coupled with the recess 130. Material such as fluid fuel cantravel in through the inlet 152, through the recess 130, and out of theoutlet 154. The one or more ports 150 provide fluid communicationbetween the manifold 120 and components to which the manifold 120 iscoupled, such as, but not limited to, the fuel reservoir 108 (FIG. 1A)or the fuel cell 102 (FIG. 1A). It should be noted that it is possibleto use the manifold 120 as a fluid distribution system where there is asingle inlet and multiple outlets so that the manifold 120 feedsmultiple locations. For example, the manifold 120 could be used as ahydrogen distribution with a single inlet and multiple outlets so thatthe manifold 120 feeds multiple locations on a fuel cell layer.

In a further option, a filter element 131 can be incorporated into apart of the flow path. For example, the filter element 131 can bedisposed within the recess 130, as shown in FIG. 3A. In another option,the filter element 131 can be disposed within the ports 150, such as theinlet 152. The filter element 131 can include a porous substrate or aflow constricting element. In another option, the filter element 131 candefine the recess 130. The filter element 131 disposed within the recess130 and/or the ports 150 assists in preventing collapsing of the recess130 and/or port 150 for instance, when the fluid manifold 120 is bentaround itself or other components within the fuel cell system. Forexample, two or more recesses 130 which extend from the first side 124to the second side 126 can be disposed within the conduit layer 122. Thetwo or more recesses 130 can be formed within the conduit layer 122 suchthat they do not intersect with one another in the conduit layer 122.Alternatively, the two of more recesses 130 can be formed within theconduit layer 122 such that they do interest with one another in theconduit layer 122. The recess 130 extends along the conduit layer 122,and allows for material such as fluid to flow therethrough.

Referring again to FIG. 1A, the fluidic control system 104 includes alayered structure that has one or more featured layers. The featuredlayers 300 each include features thereon and/or therein. In an option,the featured layers 300 are sealed with one another, for example, with agas-tight seal. The term “gas-tight” may be understood to refer to abond that is impermeable to a fluid. For example, the bond may besubstantially impermeable to hydrogen at or below 340 psi or 2.5 MPa.

The features provide one or more portions of a functional component ofthe fluidic control system 104. When the featured layers 300 aredisposed adjacent to one another, features on one layer are broughttogether with features of another layer, either physically,functionally, or both and the portions of functional components broughttogether form one or more functional components for the fluid controlsystem 104. For example, a first portion of a first component is formedon a first featured layer, and a second portion of the first componentis formed on a second featured layer. The first featured layer and thesecond featured layer are brought together, for example, but not limitedto, by stacking the first and second featured layers, and the firstportion and the second portion are brought together to form a functionalfirst component.

The fluidic control system 104 can include one or more differentfunctional components such as, but not limited to, at least one pressureregulator component 200, check valve component 230, or flow valvecomponent formed of features of one or more featured layers 300. Thefeatures can be on a single featured layer to collectively form afunctional component. In another option, the features can be on multiplefeatured layers to collectively form a functional component. Whenmultiple featured layers 300 are used to form the functional component,it is possible to build multiple function components into a singleassembly of multiple featured layers. For instance, if a first componentis formed on three featured layers, a second or third componentrequiring three or less featured layers can be formed on the samefeatured layers, albeit remote from the features of the first functionalcomponent.

An example of a functional component is a pressure regulator component200, for instance as shown in more detail in FIG. 4. The pressureregulator component 200 is formed, in an option, on multiple featuredlayers 300, where features on each layer 300 provide a portion of thepressure regulator component 200. In an example, the featured layers 300includes, but is not limited to, one or more of a first layer 204, asecond layer 206, a third layer 208, or a fourth layer 209. The secondlayer 206 is disposed between the first layer 204 and the third layer208, and the third layer 208 is disposed between the second layer 206and the fourth layer 209. It should be noted that fewer or more thanfour layers can be used for the pressure regulator component 200. Thelayers can be formed of relatively thin sheets of material. Suitablematerials include, but are not limited to, metal, elastomeric material,plastic rubber, copper, copper beryllium alloy, aluminum, stainlesssteel, acrylic, silicon, olefins, epoxies, polyester, brass,polyvinylidenefluoride (PVDF), hexafluoropropylene vinyldyne fluoridecopolymer or combinations thereof.

The pressure regulator component 200 is defined in part by a first side210 and a second side 212. In an option, the first layer 204 forms thefirst side 210, and the fourth layer 209 forms the second side 212. Thefirst side 210 and/or the second side 212, in an option, can beconfigured to cooperatively interact with adjacent components of thefuel cell system. For example, the faces can be used to interface toplanar fluid distribution manifolds, or face seals can be placed aroundthe outlet 221 etc.

The first, second, third, and fourth layers 204, 206, 208, 209correspond to featured layers of the fluidic control system 104. Itshould be noted that although FIG. 4 illustrates a single pressureregulator component 200 formed of features of the featured layers, it iscontemplated that multiple regulators can be formed on the same layers,resulting in co-planar regulators. For instance, at least one primarypressure regulator component and one or more secondary regulators can beformed on the same layers. The pressure regulator component 200 canfurther include a switch, such as valve 209 of FIG. 9, allowing for theoperation of the fluidic control system 104 to switch between using theprimary pressure regulator component to using the primary pressureregulator component and one or more secondary regulators. The use of thethin sheets or layers to make the primary pressure regulator componentsand secondary pressure regulator components allow for multipleregulators to be fabricated at the same time, and further allow for theoutput pressure of the regulators to be set, and can be set, at least inpart, on the relative size of the first layer 204, the thickness of thelayer, the elasticity of the layer, a flexibility of the layer, orcombinations thereof.

The pressure regulator component 200 has a high pressure inlet 221 and alow pressure outlet 223. The layered structure of the pressure regulatorcomponent 200 allows for the outlet pressure to be regulated while theinlet pressure can vary. Referring again to the first layer 204, it canserve a number of functions, and includes a number of features thereon.For instance, it provides a diaphragm 220 and a cap to a low pressureplenum 214 for the pressure regulator component 200, where the lowpressure plenum 214 is formed between the first layer 204 and the secondlayer 206. The first layer 204 is formed, in one option, of elasticallydeformable material, and further optionally actuates the regulator valve216 through the actuation member 228 via the elastically deformablematerial. Suitable materials include, but are not limited to,elastomeric material, plastic rubber, copper, copper beryllium alloy,aluminum, stainless steel, brass, or combinations thereof. In anotheroption, actuation of the regulator valve 216 can be varied via athickness of the layer 204, for example, where layer 204 is an elasticcomponent. The first layer 204 further provides an elastic spring forceto counteract the force from pressure in the low pressure plenum 214. Inan option, elastic stiffness of the first layer 204 determines theoutput pressure of the regulator. The pressure regulator component 200further includes an actuation member 228, where the actuation member 228is disposed through an opening 201 of the second layer 206.

The actuation member 228 provides a contact between the valve 216 andthe elastically deformable material of the first layer 204. In anexample, the actuation member 228 includes a member that is disposedbetween the valve 216 and the first layer 204, or the member can beintegral with the first layer 204, or formed on or as part of the firstlayer 204. In another option, the actuation member 228 can be formedintegrally or as part of layer 208. In an option, the actuation member228 includes a sphere or a ball (FIG. 7C) disposed between the firstlayer 204 and the valve 216. In another option, the actuation member 228includes a projection disposed between the first layer 204 and the valve216. When pressure in the low pressure plenum 214 drops below thedesired output pressure of the regulator, the diaphragm 220 of the firstlayer 204 presses against the actuation member 228, such as the ball(FIG. 7C), and the actuation member opens the valve 216.

Several options for the actuation member 228 are possible. For instance,in an option, the actuator can be made integral with one of thediaphragm 220. In another option, the actuator can be formed of a springmember, such as, but not limited to a leaf spring. The leaf springoptionally cantilevers, and forms the actuator. In another option, aspring member is disposed adjacent the sealing valve. In another option,the actuator can include shape memory alloy material, allowing forfurther options for actuation of the actuator. In yet another option,the actuator is a layer having a pinch shape, providing a projectiontherefrom. The shape can also be a ball member, or other shapes. Inanother option, compressible material, including, but not limited to, aspring, is disposed on a bottom layer, such as the fourth layer 209, andoptionally in the relaxed position places the valve in a sealingposition.

Referring to the second layer 206, the second layer 206 includes anumber of features such as a portion of the low pressure plenum 214, andseparates the low pressure plenum 214 from the high pressure plenum 215.In yet another option, the second layer 206 further provides a sealingseat 218 for the regulator valve 216. The third layer 208 defines aportion of the high pressure plenum 215, in further cooperation with thesecond layer 206 and the fourth layer 209. The third layer 208 furtherincludes the regulator valve 216.

The regulator valve 216 seals the opening 201 within the regulator 200.In an option, the valve 216 is formed within layer 208, such that thevalve 216 is integral with the layer 208 without the need foradditional, discrete components. In another option, the valve 216 formedwith the layer 208 can also serve as the actuation member 228. In afurther option, the valve 216 includes a body 222, a seal 224, and aspring member 226. The body 222 has a seal 224 therein, for example,that is molded therein. The body 222 is coupled with the spring member226, for example a cantilever spring, which allows for the valve 216 tobe moved from the closed position to the open position, and from theopen position to the closed position. The spring member 226 can beformed for example by etching, stamping, laser cutting, die cutting,deposition, printing, machining, molding, and/or electroforming themember in the layer allowing for a spring-like attachment within layer208. Other options for the spring member 226 include, but are notlimited to, a deformable member such as a ball, an elastomeric ordeflectable region on layer 209, a member, such as a deformable memberbelow the valve 216, or as part of layer 209.

The spring member 226 and the valve 216 are disposed within the highpressure plenum 215. A fourth layer 209 of the regulator 200 is disposedadjacent to the third layer, and caps the outer portion of the valve216, for example the bottom of the valve 216, and optionally provides aninlet 221 and an outlet 223 for the regulator 200. The inlet 221 isfluidly connected with the high pressure plenum 215, and the outlet isfluid connected with the low pressure plenum 214, for instance, throughports disposed within the second layer 206 and the third layer 208.

In an example operation of the pressure regulator component 200, fluid,such as fuel, enters the inlet 221 and fluid from the inlet 221pressurizes the high pressure plenum 215. The fluid further passesthrough the open regulator valve 216 into the low pressure plenum 214.The valve 216 is open due to the low pressure in the low pressureplenum. As the low pressure plenum 214 increases in pressure, firstlayer 204 is deflected toward 229 until the actuation member 228 pullsfree from the regulator valve 216, closing the valve 216 against theseat 218, and limiting pressure in the low pressure plenum 214. Pressurein the low pressure plenum 214 drops as fluid in the low pressure plenum214 drains through the outlet port 223. This causes the first layer 204to deflect away from 229, causing the actuation member to reopen theregulator valve 220 and start the cycle over again.

As mentioned above, the fuel system 104 includes one or more microplanar fluidic components, including, but not limited to a pressureregulator component 200 and check valve component. The check valvecomponent can be used for filling a fuel reservoir. FIG. 5 illustrates across section of an example of a check valve component 230 having one ormore featured layers 300. For instance, the featured layers of the checkvalve component 230 includes three layers, such as a first layer 232, asecond layer 234, and a third layer 236, where the second layer 234 isdisposed between the first layer 232 and the third layer 236. It shouldbe noted that the featured layers of the check valve component 230 canbe formed on the same featured layers of the other fluidic controlcomponents, including, but not limited to the pressure regulatorcomponent, the manifold, etc.

The first layer 232, in an option, provides a cap to the check valvecomponent 230. The second layer 234 includes an elastomeric member 238,and the third layer 236 has an inlet port 240 and an outlet port 242therein. It should be noted the inlet port 240 and the outlet port 242can be formed on different featured layers. The elastomeric member 238is compressed against the inlet port 240, and seals the inlet port 240.In an option, the elastomeric member 238 is formed as a feature in layer234. In another option, the elastomeric member 238 is a separatecomponent inserted in to a featured formed in layer 234. In yet anotherembodiment, the elastomeric member 238 includes the entire layer.

Layers 232, 234 and 236 are made from one or more of materialsincluding, but not limited to metal, elastomeric material, plasticrubber, copper, copper beryllium alloy, aluminum, silicon, stainlesssteel, acrylic, olefins, epoxies, polyester, brass, PVDF,hexafluoropropylene vinyldyne fluoride copolymer or combinationsthereof. and are optionally formed by etching, stamping, laser cutting,die cutting, deposition, printing, machining, molding, orelectroforming. Layer 234 can be formed, for example by molding oretching material from elastomeric material. Layer 238 is less rigid thanlayers 232 and 236 so that pressurized fuel can deform layer 238 awayfrom the inlet 240.

During filling of a reservoir, such as a fuel reservoir, pressurizedfluid such as fuel is applied to the inlet port 240 of the check valvecomponent 230. For example, in filling the reservoir, the fluid manifoldinteracts with or can be coupled to the fuel cell or other systemcomponents using adhesives working over comparatively large surfaceareas to that the force due to internal fluidic pressures that isforcing the components apart is easily overcome by the strength of theadhesive bond. A high internal pressure can be counteracted with a bondthat has a relatively low tensile strength.

In filling the reservoir, devices for detachably coupling, such as apressure activated valve, can be used. For example, pressure activatedone-way valve allows a flow of fluid, for example, fluid fuel, into thefluid enclosure for a fuel storage system. The flow of fuel is allowedinto the fluid reservoir during refueling, but does not allow fuel toflow back out of the fuel reservoir. In an option, flow of fuel ispermitted to flow back out of the fluid reservoir if the fluid reservoiris over pressurized with fuel.

An external refueling device can form a seal against a portion of thesealing surface, for example, around the inlet port with a seal, such asan o-ring or gasket. Fuel is introduced into the fluid control system,and the fluidic pressure of the fuel compresses the compressible memberand breaks the seal between the compressible member and the outsidecover. In another option, an environment surrounding the exterior of theoutside cover may be pressurized with fuel to force fuel through therefueling valve assembly and into the fuel reservoir.

When the fueling process is complete, the refueling fixture is removedfrom the valve assembly, and the valve becomes closed. For example, thecompressible member decompresses, and fluidic pressure from the fuelreservoir through the fuel outlet port exerts pressure on to thecompressible member and presses the compressible member against theoutside cover. The decompression of the compressible member and/or thefluid pressure from the reservoir creates a seal between thecompressible member and the outside cover such that fuel does not flowpast the compressible member and into the fuel inlet port. In anotheroption, the compressible member and/or the fluid diffusion member can bedesigned to intentionally fail if the pressure in the fuel reservoirbecomes too great, or greater than a predetermine amount.

In another option, a fluid coupling assembly can be used to couple thesystem with another component. The coupling assembly includes a firstcoupling member, a second coupling member, and a seal membertherebetween. The first coupling member and the second coupling memberare magnetically engagable, such as by way of a first magnetic memberand a second magnetic member having attracted polarities. The engagementof the first coupling member and the second coupling member opens afluid flow path therebetween. When the coupling members are disengaged,this fluid flow path is sealed. Additional examples and details can befound in commonly owned co-pending entitled MAGNETIC FLUID COUPLINGASSEMBLIES AND METHODS, filed Nov. 7, 2007, having Ser. No. 11/936,662,and having attorney docket no. 2269.056US1 which is incorporated byreference in its entirety.

Referring again to FIG. 5, pressure from the fluid deflects theelastomeric member 238 allowing fluid to pass by the member 238 and intothe valve plenum 282 that surrounds at least a portion of the member238. Fluid optionally travels from the plenum 282, through the outletport 242, and directed toward a reservoir, for example, through amanifold 120 (FIG. 1A). When the source of the pressurized fluid isremoved from the inlet port 240, the elastomeric member 238 seats againagainst the inlet port 240, and prevents fuel from flowing back outthrough the inlet port 240. In an option, the check valve component 230is coupled with a fluid manifold, for example, along the third layer236.

The fluidic control system 104 (FIG. 1A) further includes one or moreflow valve components for example, to shut off fuel, and/or to directthe fuel through the system. The flow valve component is formed on anumber of featured layers, where the featured layers have features.Similar to the check valve component, the flow valve component can beformed on the same featured layers of the pressure regulator componentand/or the check valve component. The flow valve component can beactuated using a mechanical actuation, or a chemical actuation. Inanother option, the flow valve component can be actuated usingelectrical actuation. FIG. 6 illustrates an example of an electricallyactuated flow valve component 260 that has one or more layers 262therein. In an option, the flow valve component 260 includes a firstlayer 264, a second layer 266, a third layer 268, and a fourth layer270. The first layer 264 provides a cap for the flow valve component260. The second layer 266, in an option, includes features to activateopen and closed states for a feature on an adjacent layer. For instance,the second layer 266 includes a printed resistive circuit layer. Thesecond layer 266 can be used to control the opening and closing of theflow valve component 260. The third layer 268 provides actuation foropen and closed states, and is, for example, formed of shape memoryalloy, and can be triggered by the second layer 266, for example. Thefourth layer 270 provides a valve seat 272, inlet and outlet ports 274,276, and a base 278 for optional attachment to a fluid manifold 120(FIG. 1A). In an open state, energy such as heat is applied to theactuator 279, and the actuator 279 is moved away from the valve seat272. For example, electrical current flowing through a resistive layercan be used to heat the shape memory alloy, allowing for the actuator279 to curve up and away from the valve seat 272. In the closed state,the actuator 279 is pressed against the valve seat 272, and seals thevalve seat 272. For instance, the shape memory alloy is allowed to cool,and return to an undeformed state to press against the valve seat 272.

The fluidic control system 104 is formed of featured layers 300 thatinteract with one another, and includes a number of components formed asa result of the interaction of the layers 300. The components of thefluidic control system 104, including, but not limited to, at least oneor more of a pressure regulator component, a check valve component, or aflow valve component are each formed on one or more featured layers 300,and may share featured layers 300. For example, features of the pressureregulator component may be on the same featured layer 300 as the atleast one check valve component and/or the flow valve component.

FIGS. 7A, 7B, and 7C illustrates an example of the fluidic controlsystem 104 with featured layers 300, for example featured layers 301,302, 303, 304, and 305, each having features. The fluidic control system104 includes at least one of the following components: a pressureregulator component 200, the flow valve component 260, a charge valvecomponent 340, or a pressure relief component 322. It should be notedthat one or more of the components can be included, and are optionallyco-planar with each other.

The featured layers 300 form compound structures providing forintegrated fluidic circuits that include layers with multiple featuresstacked and joined together. The features of the featured layers 300collectively form functional components. The layers can be mounted on anexternal manifold, or the manifold can also be integrated as part of thelayered structure. For example, portions of the layered structure cancontinue through multiple layers forming a conduit through the layers,and can interface with components such as fuel reservoir and the fuelcell.

The layers can be formed and assembled as an array of parts heldtogether on a larger sheet. The layers are made with various processessuch as, but not limited to, etching, stamping, laser cutting diecutting, deposition, printing, machining, molding or electroforming,allowing for ease of manufacture of a large number of components. Forexample, sub systems can be assembled at the same time, and then removedfrom an array of several of the same or similar sub systems. Multiplecomponents can be built next to each other on the same layer.Furthermore, multiple assemblies of components can be built concurrentlyfrom the same sheet of material forming the layer, and then cut out tomake individual fluid systems. The layers can be held and sealedtogether for example, but not limited to, using one or more of thefollowing techniques: gluing, adhesive bonding, thermal bonding,diffusion boding, welding, or soldering. The layers in an option,include one or more bonding regions allowing for flowing adhesives orother bonding agents so that layers can be bonded without the functionalcomponents, the conduit channels, or ports also being bonded. In afurther option, the one or more featured layers include barrierfeatures, such as, but not limited to, physical barriers such as ridges,or recesses and/or chemical barriers that separate bonding regions fromfunctional regions and/or prevent bonding material from enteringfunction regions.

The layered structure is made small, nano-fabrication technologies,and/or micro fabrication technologies can be employed to produce andassemble the layers. For instance, processes for producing and/orassembling the layers include, but are not limited to, microfluicsapplication processes, or chemical vapor deposition for forming a mask,and followed by a process such as etching. In addition, materials foruse in fabricating the thin layered structure includes, but is notlimited to, silicon, polydimethylsiloxiane, parylene, or combinationsthereof.

The layers are small and planar. For example, the thickness of the layeris about 10-500 micron. The layer is highly planar such that a width ofa planar portion of the layer is greater than thirty times the thicknessof the layer. In another option, the width of the layer is greater thanthree times the thickness of the layer. It should be noted other rangesare possible.

When the layers are placed adjacent to one another, the layers areadapted to operatively interact together. It should be noted that one ormore of the components can be replaced with an array of smallercomponents. For example, an individual regulator can be replaced with aregulator component array. The regulator array may provide a failuretolerant system, as some of the array may fail to function, and yet theoverall system can continue to operate. It further addresses the abilityto distribute fuel in an effective way, for instance the regulator arraycan be distributed in the fuel cell or fuel reservoir to reduce issuescaused by poor fuel distribution.

One example of the components formed by the featured layers includes apressure regulator component 200. Features which form portions of thepressure regulator component 200 are formed on layers 301, 302, 303, and304. For example, at least a portion of the high pressure plenum isformed on layer 301, at least a portion of the valve 216 is formed onlayer 302, at least a portion of the low pressure plenum 214 is formedon layer 303, and the diaphragm 220 is formed on layer 304. The featuresare formed on the various layers 301, 302, 303, and 304, and the layersare brought together, for example, the layers are disposed adjacent toone another, and are optionally joined. The features interact withfeatures on the same or other featured layers and collectively form afunctional component, such as the pressure regulator component 200.Other components can be formed on the various layers, including layers301, 302, 303, and 304 such that features of one component share a layerwith features of another component, as further discussed below. Forexample, the features and resulting functional components are co-planar.

During operation of the fluidic control system 104, fluid such as fuelenters the regulator 200 through an inlet port 221 and enters the highpressure plenum 215. The high pressure plenum 215 surrounds theregulator valve 216 and spring member 226, such as three elasticmembers, hold the valve 216 closed against the valve seat unless thevalve is acted upon by the actuation member 228, such as the actuatorball. When the pressure in the low pressure plenum 214 is below thedesigned output pressure of the regulator, the diaphragm 220 pressesagainst the actuation member 228, which in turn opens the regulatorvalve 216. When the valve 216 is in the open position, fluid such asfuel can flow from the high pressure plenum 215 to the low pressureplenum 214 until the desired pressure is reached and the diaphragm 220deflects enough to allow the regulator valve 216 to close.

The fluid leaves the regulator 200 through an opening 330 and enters theflow valve plenum 332 of the flow valve component 370. The flow valvecomponent has features on different featured layers that collectivelyform a functional component, such as the flow valve component. The flowvalve component, in this example, is similar to the regulator valve 216.However, rather than being actuated upon by an actuation member 228 asin the regulator valve 216, the flow valve component is opened with apin pressed against the flow valve component through the outlet port334. The outlet port 334 can be connected to a fuel cell 102 (FIG. 1A),for example, via a manifold 120 (FIG. 1A).

The charge valve component 340 is another component having featuresformed on one or more featured layers 300 that interact and collectivelyform a functional component, as shown in FIG. 7C. The charge valvecomponent 340 includes a spring member 342 of featured layer 302, suchas a rubber member, pressed sealingly against the charge port 344 offeatured layer 303. When charging pressure is applied to the charge port344, the spring member 342 is deformed away from the charge port 344 bythe charge pressure allowing gas to flow by and enter the port 346 offeatured layer 301. The port 346 is optionally fluidly connected to thefuel reservoir 108 (FIG. 1A).

Another component that can be made using a number of different featuredlayers 300 includes a pressure relief component 340. The pressure reliefcomponent 350 includes a spring member 352 of featured layer 302, suchas a rubber member, that seals against a port 354 of featured layer 301.The port 354 is fluidly connected to the fuel reservoir 108 (FIG. 1A)and when the reservoir pressure is exceeds a predetermined value, thespring member 352 is deformed away from the port 354 by the pressure infuel reservoir 108. This allows for fluid such as fuel to flow by, passthrough ports formed by featured layers 303, 304, and enter the port 360of featured layer 305, which exhausts to the atmosphere. In an option,the regulator 200, the charge valve component 340, and the pressurerelief component 350 communicate with the fuel reservoir 108 separatelythrough ports 221, 346, 354. In another option, an additional manifoldlayer below layer 301 can be added, and the ports can be combined intofewer ports, such as one port.

FIGS. 8A and 8B illustrate an example of the fluidic control system 104formed of featured layers 300 including features. The featured layers300 can be formed by various techniques, such as, but not limited toetching, etching, stamping, laser cutting, die cutting, deposition,printing, machining, molding, or electroforming, etc. An array offeatures can be formed on each featured layer, and an array offunctional components can be formed by bringing the layers together. Inan example, a second featured layer is stacked on the first featuredlayers, and the array of functional components is formed. Optionally,the second featured layer is joined with the first featured layer withvarious techniques such as, but not limited to, thermal bonding,adhesive boding, soldering, welding, ultrasonic welding, diffusionbonding, heat sealing, etc.

The featured layers 300 include features therein or thereon which formportions of a component of the fluidic control system. Examples ofcomponents of the fluidic control system 104 include a check valvecomponent 230, a primary regulator 213 and at least one secondaryregulator 217.

The primary and secondary regulators 213, 217 have similar structure, inan option. Features which form portions of the pressure regulatorcomponents 213, 217 are formed on layers 301, 302, 303, and 304. Forexample, at least a portion of the high pressure plenum is formed onlayer 301, at least a portion of the valve 216 and member 226 are formedon layer 302, at least a portion of the low pressure plenum 214 isformed on layer 303, and the diaphragm 220 is formed on layer 304. Thefeatures are formed on the various layers 301, 302, 303, and 304, andthe layers are brought together, for example, the layers are disposedadjacent to one another, and are optionally joined. The featuresinteract with features on other featured layers and collectively form afunctional component, such as the pressure regulator components 213,217. The pressure regulator components 213, 217 are optionallyco-planar.

The check valve component 230 is formed of features formed on, in ordisposed on multiple featured layers 300. The check valve component 230can be used for fueling a fuel reservoir of the fuel cell. Featuredlayer 303, in an option, provides a cap 391 to the check valve component230. The featured layer 302 includes an elastomeric member, and thethird featured layer 301 has an inlet port 240 and an outlet port 242therein. It should be noted the inlet port 240 and the outlet port 242can be formed on different featured layers. The elastomeric member iscompressed against the inlet port 240, and seals the inlet port 240.

During filling of a fluid, for example fueling of a fuel cell,pressurized fluid such as fuel is applied to the inlet port 240 of thecheck valve component 230. The pressure from the fluid deflects theelastomeric member allowing fluid to pass by the member and into thevalve plenum that surrounds at least a portion of the member. Fluidoptionally travels from the plenum, through the outlet port 242, anddirected toward a reservoir, for example, through a manifold 120 (FIG.1A). When filling is complete, the elastomeric member seats against theinlet port 240, and prevents fluid from flowing back out through theinlet port 240. In an option, the check valve component 230 is coupledwith a fluid manifold, for example, along the featured layer 301.

Referring to FIG. 9, a system layout of a fluidic control system 104 isillustrated. In an option, the fluidic control system 104 includes oneor more of a fuel refueling inlet 202, a check valve component 205, apressure selection valve 207, an on/off valve 209, and/or an outlet 290,for example, to the fuel cell 102 (FIG. 1A). The on/off valve 209 turnsoff the fuel supply if the fuel cell system is turned off. The fuelsystem 104 further optionally includes a connection 211 to fuelreservoir 108 (FIG. 1A).

The fluidic control system 104 optionally includes at least one pressureregulator component 200. In an example, the at least one pressureregulator component 200 includes at least one primary pressure regulatorcomponent 213. In a further option, the at least one pressure regulatorcomponent 200 includes at least one primary pressure regulator component213 and/or at least one secondary pressure regulator component 217. Inan option, the fluidic control system 104, includes multiple pressureregulator components 200 such as multiple secondary pressure regulatorcomponents 217, or an array of secondary pressure regulator components217 alone or in combination with the primary pressure regulatorcomponent.

When the fuel cell fed by the system is able to tolerate wide variationsin inlet pressure, or when the difference between the fluid storagepressure, such as fuel storage pressure, and the demanded deliverypressure is low, a primary pressure regulator component, such as asingle, primary pressure regulator component, may be used. When the fuelcell fed by the system is unable to tolerate wide variations inpressure, the system 104 can be configured with both primary andsecondary regulators.

The primary pressure regulator component 213 steps the pressure down forthe secondary pressure regulator component 217. Further, the primarypressure regulator component 213 reduces the effect of fluctuating fuelreservoir pressure on the output of the secondary pressure regulatorcomponents 217. The primary pressure regulator component 213 and thesecondary pressure regulator component 217, and/or the two or moresecondary pressure regulator components 217 can be set to differentoutput pressures. In this configuration, one of the regulators canprovide a lower pressure for when the fuel cell is in standby operation,while another can provide a higher pressure when the fuel cell isactively operating. This option can be extended to include multiplepressures tuned to support a wide range of operating modes of the fuelcells, including the modulation of pressures for ancillary fuel cellmanagement functions such as gas purging, water management etc. Usingmultiple secondary pressure regulator components allows for digitalselection of the operating pressures, and eliminates a need for acontinuously variable pressure regulation system.

In an option, the pressure selection valve 207 controls flow to thehigher pressure secondary regulator 217 and controls the pressure of thelinked output of the multiple secondary regulators 217. If the pressureselection valve 207 is off, the output of the secondary pressureregulator components 217 is at the lower pressure, while if the valve207 is open, the output will be at the higher pressure. In an option,one or both of the secondary regulators 217 are pilot pressurecontrolled from the fuel pressure at the fuel cell 102 (FIG. 1A). Thisallows for the fuel pressure at the fuel cell to remain constant,unaffected by pressure losses in the fuel conduits between theregulators 200 and the fuel cell 102 (FIG. 1A). See also commonly ownedco-pending patent application entitled FLUIDIC DISTRIBUTION SYSTEM ANDRELATED METHODS, filed even date herewith, having Ser. No. 12/053,408and patented as U.S. Pat. No. 8,133,629, and having attorney docket no.2269.067US1, which is incorporated by reference in its entirety.

As mentioned above, two or more secondary regulators 217 can be includedin the fluidic control system 104. For example, an array of parallelsecondary regulators 217 with each having its own pressure selectionvalve would enable digital pressure control where the pressure can beincreased and decreased in increments. The regulators 217 in the arraywould each have differing output pressure.

The fuel cell pressure is easily fed back through the conduit back tothe physical location of the pressure regulator components.Additionally, the unregulated gas pressure can be used to providemechanical power into the system for actuation of valves due to themultiple stages. This allows for the system to operate with a minimum ofexternal energy inputs. In a further option, the pressure regulatorcomponents can be made at the same time from a single sheet of layeredmaterial, it is possible to have a single inlet feeding multipleregulator components with multiple outlets,

Methods for use with or for making the above-described device are asfollows. For instance, in an option, the method includes a method forforming a fluidic control system, including forming at least one firstfeature on one or more featured layers, forming at least one secondfeature on any of the one or more featured layers, and interactivelyassociating the at least one first feature with the at least one secondfeature and forming at least one functional component. In an option, themethod includes interactively associating the at least one first featurewith the at least one second feature includes stacking the one or morefeatured layers, where forming the at least one first feature or the atleast one second feature includes etching, stamping, laser cutting, diecutting, deposition, printing, machining, molding, or electroforming afeature on the one or more featured layers.

In a further option, forming at least one functional component includesforming one or more of at least one pressure regulator component, atleast one check valve component, at least one flow valve component, atleast one conduit component, pressure relief component, or a thermalrelief component. In yet another option, forming the at least onefeatured layer includes forming the at least one featured layer ofmetal, of elastomeric material, plastic rubber, copper, copper berylliumalloy, aluminum, stainless steel, acrylic, silicon, olefins, epoxies,polyester, brass, PVDF, hexafluoropropylene vinyldyne fluoride copolymeror combinations thereof. The featured layers can be sealed together,where sealing the featured layers includes one or more of gluing,adhesive bonding, thermal bonding, diffusion boding, welding, solderingthe featured layers together or combinations thereof.

In yet another option, a method of operating a system includesfluidically coupling a fluid enclosure with a fluidic control system,the fluidic control system including at least one functional component,two or more featured layers having features, and features of any of thetwo or more featured layers interactively form the at least onefunctional component, where the method further includes transferringfluid from the fluid enclosure to the fluidic control system. The methodoptionally includes transferring via a strain relieving interface,and/or transferring fluid from the fluid enclosure to the fluidiccontrol system includes transferring fluid from a fuel cartridge, and/ortransferring fluid to at least one fuel cell. In yet a further option,transferring fluid from the fluid enclosure includes transferring fluidvia a fluid manifold to the at least one fuel cell, and/or transferringfluid from a fluid plenum of a fuel cell via a fluid manifold to thefluid control system. In a further option, the fluid is transferredbased on a fluid flow through a feedback channel of the fluid manifold.

The method further optionally includes fluidly coupling the fluidiccontrol system with a charge port, where optionally, fluidly couplingthe fluidic control system with the charge port includes fluidlycoupling the fluidic control system with the charge port via a fluidmanifold.

The fluidic control system is a layered structure where features of thevarious layers interact to accomplish functions for the fluidic controlsystem, such as, but not limited to, the functions of a pressureregulator component, a check valve component, a flow valve component,and a fluid conduit. The fluidic control system offers efficientdistribution of fluids, for instance in micro fluidic applications. Thesmall scale of the layers allows for multiple identical components to beincluded, providing for increased reliability and functionalflexibility.

In the description of some embodiments of the invention, reference hasbeen made to the accompanying drawings that form a part hereof, and inwhich are shown, by way of illustration, specific embodiments of theinvention that may be practiced. In the drawings, like numerals describesubstantially similar components throughout the several views. Theseembodiments are described in sufficient detail to enable those skilledin the art to practice the invention. Other embodiments may be utilizedand structural, logical, and electrical changes may be made withoutdeparting from the scope of the invention. The following detaileddescription is not to be taken in a limiting sense, and the scope of theinvention is defined only by the appended claims, along with the fullscope of equivalents to which such claims are entitled.

1-53. (canceled)
 54. A fluidic control system a plurality of layersstacked on each other and joined together, a flow inlet and a flowoutlet, wherein the plurality of layers comprises a top layer, a bottomlayer, and a heating layer and an actuation layer disposed between thetop and bottom layers, wherein the actuation layer comprises a heatsensitive shape-memory alloy and the heating layer conducts heat to theactuation layer to move the actuation layer between an openconfiguration where a fluid can flow through the fluidic control systemand a closed configuration where a fluid cannot flow through the fluidiccontrol system.
 55. The fluidic control system of claim 54, wherein theheating layer comprises a resistive circuit layer that is heated byelectrical current.
 56. The fluidic control system of claim 55, whereinthe heating layer comprises a printed resistive circuit layer.
 57. Thefluidic control system of claim 54, wherein the flow inlet and the flowoutlet are formed on the bottom layer.
 58. The fluidic control system ofclaim 54, wherein a valve seat is formed on the bottom layer and whereinsaid valve seat forms a seal with the actuation layer to move thefluidic control system to the closed configuration.